Method and apparatus for associating on demand certain selected media and value-adding elements

ABSTRACT

A media printer such as, for example, a thermal transfer media printer is disclosed. In one embodiment, the printer selectively programs RFID transponders, and then embeds them into conventional on-demand printed media between the adhesive layer and the release liner. Selective configuration of each printed media sample by addition of value-adding elements may be performed independently for each media sample, under software control during processing of each media sample format print control program. An add-on mechanism is disclosed that can be operatively attached to a conventional media printer. This allows value-adding elements such as RFID transponder labels to be selectively applied at precise locations on the printed surface of on-demand printed media in connection with existing printers.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation of U.S. application Ser. No.09/969,114 that was filed on Oct. 1, 2001.

BACKGROUND OF THE INVENTION

[0002] The present invention concerns, in a general sense, a method andapparatus by which, both selectively and on-demand, individual labels,tickets, tags, cards, and the like (hereinafter collectively and inindividual units referred to as “media”, or individually as “mediasamples”) having selected characteristics may be custom configured bycausing one or more value-adding elements that have chosencharacteristics to be associated with said media. More particularly, theinvention is directed to method and apparatus for selectivelyincorporating a value-adding element such as, for example, a radiofrequency identification (hereinafter called RFID) transponder withindividual media samples on a programmed, on-demand basis.

[0003] Other types of value-adding elements that could be incorporatedinto media samples include, for example, shipping documents; parts to beinventoried, stored or shipped; promotional devices such as coupons,tokens, currency or other objects having a value to the recipient;integrated circuits on labels with leads to be connected to printedantennas; and attached or embedded attached objects that have associatedinformation on the printed media relating to their identification oruse.

[0004] A thermal transfer printer is typically used to print individualmedia samples. Referring to FIG. 1, a side view of a standard thermaltransfer printer mechanism 10 is illustrated. A label carrier 12 (alsogenerally referred to as a release liner) carries adhesive-backed,(typically unprinted) diecut labels 14 through the mechanism. Typically,the top surface of each label is printed with a pattern of ink dots froma thermal transfer ribbon 16 melted onto the label surface as the ribbonand label pass under a computer-controlled thermal printhead 18.

[0005] An elastomer-coated platen roller 20 typically is driven by astepping motor (not shown) to provide both the movement force for theribbon and label by means of a friction drive action on the labelcarrier 12, as well as acting as the receiver for the required pressureof the printhead on the ribbon-label sandwich. This pressure assists intransferring the molten ink dots under printhead 18 from the thermaltransfer ribbon 16 onto the diecut label 14 surface.

[0006] The thermal transfer ribbon 16 is unwound from a printer ribbonsupply 22, and is guided under the thermal printhead 18 by idler rollers24. After the ink is melted from the ribbon 16 onto the printed diecutlabel 26, the spent ribbon is wound on a printer ribbon take-up spindle28.

[0007] Typically, a media exit 30 is located immediately after theprinthead 18. The now-printed diecut label 26 is often dispensed on itslabel carrier 12. If a user desires that the printed diecut labels beautomatically stripped from label carrier, then an optional peeler bar32 is utilized. As the label carrier 12 passes over the sharp radius ofpeeler bar 32, the adhesive bond is broken, thereby releasing theprinted diecut label 26 from its label carrier 12. The peeled, printeddiecut label 26 is dispensed at media exit 30. The excess label carrier12 is both tensioned for peeling and rewound using optional labelcarrier take-up mechanism 34.

[0008] As will be described in detail hereinafter, an exemplaryembodiment of the present invention involves selectively and on demandassociating, in the environment of a thermal or thermal transferprinter, an RFIC transponder with a label, e.g., to create a “smart”label. Although “chipless” RFID transponders exist and may be utilizedas one example of a value-added element with certain aspects of thisinvention, the most common form of an RFID transponder used in smartlabels comprises an antenna and an RFID integrated circuit. Such RFIDtransponders include both DC powered active transponders and batterylesspassive transponders, and are available in a variety of form factors.Commonly used passive inlay transponders 36 shown in FIG. 2 have asubstantially thin, flat shape. For automatic insertion into labels, theinlay transponders 36 typically are prepared with a pressure-sensitiveadhesive backing, and are delivered individually diecut and mounted witha uniform spacing on an inlay carrier.

[0009] Inlay transponders have been used as layers of identificationtags and labels to carry encoded data, stored in a non-volatile memoryarea data, that may be read wirelessly at a distance. For example, acamera having a radio-frequency identification transponder that can beaccessed for writing and reading at a distance is disclosed in U.S. Pat.No. 6,173,119.

[0010] The antenna 38 for an inlay transponder 36 is in the form of aconductive trace deposited on a non-conductive support 40, and has theshape of a flat coil or the like. Antenna leads 42 are also deposited,with non-conductive layers interposed as necessary. The RFID integratedcircuit 44 of the inlay transponder 36 includes a non-volatile memory,such as an EEPROM (Electrically Erasable Programmable Read Only Memory);a subsystem for power generation from the RF field generated by thereader; RF communications capability; and internal control functions.The RFID integrated circuit 44 is mounted on the non-conductive support40 and operatively connected through the antenna leads 42. The inlaysare typically packaged singulated or on a Z-form or roll inlay carrier46 as shown in FIG. 2.

[0011] It is known how to utilize on-press equipment for insertion oftransponders into media to form “smart labels,” and then to printinformation on a surface of the smart labels. See, for example, anapplication white paper entitled “RFID Technology & Smart Labels,” datedSep. 14, 1999, P/N 11315L Rev. 1 of Zebra Technologies Corporation. Seealso, for example, a document entitled “A White Paper On The DevelopmentOf AIM Industry Standards For 13.56 MHz RFID Smart Labels And RFIDPrinter/Encoders” by Clive P. Hohberger, PhD, that is dated May 24,2000. Both of these documents are incorporated by reference into thisapplication as if fully set forth herein.

[0012] It also is known how to utilize label applicator equipment toattach pressure-sensitive labels to business forms. Such equipment hasbeen commercially available on the U.S. market from several companiesfor more than one year prior to the filing of this application.

[0013] Zebra Technologies Corporation is a leading manufacture of anumber of printer related products, including a number of on-demandthermal transfer printers that incorporate a number of the aspects ofthe technology that is disclosed in the two above-referenced whitepapers. An example of such a “smart label” printer commerciallyavailable for more than a year prior to the filing of this applicationincludes Zebra model number R-140.

[0014] Such products are satisfactory for their intended uses. However,further improvements are desired. Certain features and advantages of theinvention will become apparent from the description that follows.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The objects and advantages of the present invention will becomemore readily apparent to those of ordinary skill in the relevant artafter reviewing the following detailed description and accompanyingdrawings, wherein:

[0016]FIG. 1 is a side, schematic view of a standard thermal transferlabel printer mechanism;

[0017]FIG. 2 is a schematic view of a plurality of passive inlay-typeRFID transponders as delivered with an adhesive backing on an inlaycarrier;

[0018]FIG. 3 is a side, schematic view of a thermal transfer printerthat incorporates a number of aspects of an exemplary embodiment of thepresent invention disclosed in this application;

[0019]FIG. 4 is a front, sectional view of a portion of the thermaltransfer printer shown in FIG. 3 detailing a tamping applicatormechanism;

[0020]FIG. 5 is a front, sectional, schematic view of the thermaltransfer printer shown in FIG. 3, wherein a transponder dispensingmechanism is disposed in a fully retracted initial position;

[0021]FIG. 6 is a schematic, block diagram of some of the key electronicsubsystems and components of the thermal transfer printer shown in FIG.3;

[0022]FIG. 7 is a program flow-chart that illustrates certain keyprogram steps that are executed by the processor unit shown in FIG. 6for each print job that is performed by the thermal transfer labelprinter shown in FIGS. 3-6;

[0023]FIG. 8 is a front, sectional, schematic view of the thermaltransfer printer shown in FIG. 3, wherein the transponder dispensingmechanism shown in FIG. 5 is disposed in an extended position so that anRFID transponder is positioned in a desired position and orientationwith respect to a delaminated diecut label printed by the thermaltransfer printer;

[0024]FIG. 9 is a front, sectional, schematic view of the thermaltransfer printer shown in FIG. 5, wherein the tamping applicatormechanism detailed in FIG. 4 is utilized to permanently affix aprogrammed RFID transponder to a media sample that is to be printed bythe thermal transfer printer mechanism and wherein a linear actuator isused to retract the dispensing mechanism to peel the inlay carrier fromthe back of the programmed transponder thereby exposing its adhesivelayer;

[0025]FIG. 10 is a side, sectional, schematic view of the thermaltransfer printer shown in FIG. 3, wherein a diecut label/programmedtransponder sandwich is formed and relaminated to the diecut labelcarrier;

[0026]FIG. 11 is a side schematic view of a thermal transfer printermechanism, similar to that disclosed in FIG. 3, that incorporates anumber of aspects of a further exemplary embodiment of the presentinvention disclosed in this application, and that allows adhesive-backedvalue-adding devices such as RFID transponders to be affixed to stiffmedia that does not include its own adhesive layer;

[0027]FIG. 12 is a side schematic view of the thermal transfer printershown in FIG. 11, wherein an adhesive-backed, programmed RFIDtransponder is disposed in a dispensing position with respect to thevalue-adding mechanism;

[0028]FIG. 13 is a side schematic view of the thermal transfer printershown in FIG. 11, wherein an adhesive-backed, programmed RFIDtransponder is affixed to a stiff media; and

[0029]FIG. 14 is a side schematic view of the thermal transfer printershown in FIG. 11, wherein the stiff media, upon which anadhesive-backed, programmed RFID transponder is affixed, is advanced toa dispensing position;

[0030]FIG. 15 is a flow-chart that illustrates certain key program stepsthat are executed by the processor unit shown in FIG. 6 for each printjob that is performed by the thermal transfer printer shown in FIGS.11-14;

[0031]FIGS. 16A though 16D are schematic views of two types of RFIDintegrated circuit labels and their attachment to two correspondingtypes of printed antennae in order to form actual RFID transponders in aprocess using an exemplary variation of the thermal transfer printershown in FIGS. 11-15;

[0032]FIGS. 17A and 17B are schematic views of the front and reversesides postcard set media that is on-demand printed and to which variousvalue-added elements are added in a production process according to anexemplary embodiment of the present invention;

[0033]FIG. 18 is a representation of the four value-added elements whichare added in certain combinations to the postcard set media of FIG. 17by the exemplary production process that is shown in FIG. 19;

[0034]FIG. 19 is an overhead schematic view of an exemplary productionprocess incorporating forms of two exemplary embodiments inventionembodiments that is used for selectively and on-demand configuring thepostcard media of FIG. 17 by addition of one or more value-addedelements of FIG. 18;

[0035] FIGS. 20-23 are side, schematic views of a thermal transferprinter mechanism that incorporates a number of aspects of the presentinvention disclosed in this application, and that an RFID transponder tobe selectively and on demand, under program control, RFID transponderencoded, and attached to an adhesive backed previously printed diecutlabel; and

[0036]FIG. 24 is a side, schematic view of a thermal transfer printermechanism, similar to FIGS. 20-23, that allows an RFID transponder to beselectively and on demand, under program control, RFID transponderencoded, and attached to a linerless media.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0037] While the present invention is susceptible of embodiment invarious forms, there are shown in the drawings a number of presentlypreferred embodiments that are discussed in greater detail hereafter. Itshould be understood that the present disclosure is to be considered asan exemplification of the present invention, and is not intended tolimit the invention to the specific embodiments illustrated. It shouldbe further understood that the title of this section of this application(“Detailed Description of Illustrative Embodiments”) relates to arequirement of the United States Patent Office, and should not be foundto limit the subject matter disclosed herein.

[0038] Referring to FIG. 3, a side, schematic view of a thermal transferprinter 48 that incorporates a number of aspects of the presentinvention disclosed in this application is shown. In the embodiment ofthe present invention illustrated in FIG. 3, the thermal transferprinter 48 comprises a standard thermal transfer printer mechanism thatincludes all of the components illustrated in FIG. 1. Printer 48 alsoincludes a value-adding mechanism 50 comprising the identified objects54-70 that cause a value-adding device such as, for example, aprogrammed RFID transponder 52 to be affixed to a media sample after itis printed as discussed in greater detail hereinafter.

[0039] It should be understood that value-adding mechanism 50 can bemanufactured and sold apart from the thermal transfer printing mechanism10 to allow existing thermal transfer printers to be retrofitted and,therefore, operate in accordance with a number of aspects of theinvention disclosed in this application. It also should be understoodthat, while the illustrated embodiments of the present invention aredisclosed in connection with thermal transfer printing, the presentinvention is applicable to other printing technologies.

[0040] Referring back to FIG. 3, the thermal transfer printer 48 allowsan adhesive-backed, preprogrammed RFID transponder 52 to be selectivelybonded to a printed diecut media sample (such as, for example, a printeddiecut label 26) by the value-adding mechanism 50 under program controlas discussed in greater detail hereinafter. The finished printed diecutlabel/programmed transponder sandwich (26/52) is presented at media exit30 with the label carrier 12 optionally stripped.

[0041] Immediately after printing, the printed diecut label 26 isreleased from its label carrier 12 by passing over the sharp radius ofthe peeler bar 32. The delaminating process performed by peeler bar 32exposes the adhesive on the bottom (unprinted) surface of the printeddiecut label 26.

[0042] The printed diecut label 26 then continues in a straight line asit passes over a smooth, perforated vacuum guide plate 54 of a tampingapplicator mechanism 56. A centrifugal fan 58 extracts air 60 to createa slight vacuum in the plenum 62. This causes a slight upward force tobe maintained on the printed diecut label 26 that keeps it disposedagainst the smooth perforated vacuum guide plate 54. The magnitude ofthe vacuum force is at such a level that does not impede the forwardmotion of the printed diecut label 26. Plenum 60 is extensible along acentral axis that is generally perpendicular to the path of movement ofthe label.

[0043] The delaminated label carrier 12 passes around a buffer looproller 64 used to control the flow of the label carrier 12 around atransponder dispensing mechanism 66 (FIG. 6). The buffer loop roller 64is free to float up and down, taking up and returning excess labelcarrier 12 at different times in the process.

[0044] In an exemplary embodiment, one function of the dispensingmechanism 66 is to position an adhesive-backed RFID transponder 52underneath and in operative relation to the printed diecut label 26.RFID transponder 52 is transported on the inlay carrier 46 as shown. Thetamping applicator mechanism 56 (FIG. 3) then extends the plenum 60downwardly through the use of flexible bellows 70 so that the rigid,perforated vacuum guide plate 54 lightly tamps the printed side ofprinted diecut label 26. This causes the exposed adhesive surface of theprinted diecut label 26 to be adhered to the top surface of the RFIDtransponder 52.

[0045] The label-transponder sandwich (26/52) is now advanced forwardly,and is passed through a nip 72 that is formed by upper nip roller 74 andlower nip roller 76. The nip compression both bonds the adhesive of theprinted diecut label 26 to the RFID transponder 52, and relaminateslabel-transponder sandwich (26/52) to the label carrier 12. The formeddiecut label-transponder-label carrier sandwich (26/52/12) then exitsthe value-adding mechanism 50. As is well known, the label carrier 12may be optionally stripped from the diecut label/transponder sandwich(26/52) by the use of an exit peeler bar 78 and optional label carriertake-up mechanism 34.

[0046] Typically, only the lower nip roller 72 is driven, this rollerbeing driven at the same surface speed as the platen roller 20. Thisallows, for example, printed diecut labels 26 that are longer than thegap between platen roller 20 and nip 72 to be accommodated in printer 48without deforming the printed diecut label 26.

[0047]FIG. 4 is a detailed sectional view of a portion of the tampingapplicator mechanism 56 shown in FIG. 3. A sealed case 80 and sealedflexible bellows 70 form a closed plenum 62 that contains a partialvacuum to be applied to the printed media as it passes through thethermal transfer printer 48. The atmospheric pressure on the undersideof the printed diecut label 26 thus causes the label to be temporarilyadhered to the perforated vacuum guide plate 54.

[0048] The vacuum in plenum 62 is generated by a centrifugal fan 58expelling air 60 sucked in through the holes 82 in the perforated vacuumguide plate 54, passing through internal vents 84 and 86 into blowerinlet 88. The flexible bellows 70, attached both via a drive bracket 104to the perforated vacuum guide plate 54 and a baseplate 90, allows theperforated vacuum guide plate 54 to move up and down while maintaining asealed vacuum in plenum 62.

[0049] Baseplate 90 forms a part of the housing of the thermal transferprinter 48 and on which is mounted case 80. The tamping applicatormechanism 56 is mounted on a case bracket 92, and includes a two-partsolenoid with fixed solenoid coil 94 attached to a case bracket 92, andsolenoid plunger 68 that is attached to the gas spring plunger 97 viacoupler 100. The body of gas spring 98 slides freely within a linearbearing 102 that is affixed to the perforated vacuum guideplate 54indirectly through drive bracket 104 as shown. A return spring 106between the movable coupler 100 and the fixed baseplate 90 provides aforce to return the solenoid plunger 68 and iron disc 96 to their restposition when the solenoid coil 94 is deenergized.

[0050] One function of the gas spring 98 is to transfer a constant forceto the vacuum guide plate 54 independently of the degree of plenumextension. The gas spring 98, acting together with return spring 106 andthe driven mass, also provides viscous damping of the motion of theperforated vacuum guide plate 54, decoupling it from the snap action ofthe solenoid plunger 68 when the solenoid coil 94 is energized, pullingdown iron disc 96. A gas damper or other viscous damper mayalternatively be used in place of gas spring 98 to perform the samefunction.

[0051] Alternative design concepts are available for the tampingapplicator mechanism if a compressed air source is available. Thepartial vacuum in plenum 62 may be generated by passing compressed airthrough a venturi. The tamping actuator may be an air cylinder, with acontrolled airflow in said air cylinder replacing the function of thegas spring 98 in extending downward the perforated vacuum guide plate54. Alternatively, tamping may be performed through use of an air blastthrough the perforated vacuum guide plate 54 onto the label in analternate tamping applicator mechanism 56 with an non-extensible plenum62.

[0052] Referring to FIG. 5, a sectional, schematic view of the thermaltransfer printer 48 shown in FIG. 3 is illustrated, wherein dispensingmechanism 66 is disposed in a fully retracted initial position. In theembodiment of the invention shown in FIG. 5, printer 48 includesutilizes an RF signal 108 that is emitted by transponder programmerantenna 110 to program the memory in RFID integrated circuit 44. In thefully retracted position shown in FIG. 5, the now-programmed RFIDtransponder 52 is positioned directly under the transponder programmerantenna 110.

[0053] The dispensing mechanism 66 comprises, in the illustratedembodiment of the present invention, among other things, transpondercarrier rollers 112, 113, 115 a rigid guide plate 114, and a linearactuator 116. Linear actuator 116 extends and retracts the rigid guideplate 114 so that the now-programmed RFID transponder 52 is placed underthe diecut label 26 in the desired insertion position.

[0054] To position the programmed transponder 52 properly under printeddiecut label 26, a rolamite drive mechanism 118, that is turned byrolamite stepping motor 120, is synchronized with the motion of linearactuator 116 to adjust the movement of transponder inlay carrier 46.This motion is also synchronized with the motion of a transponder supplyroll spindle 122 and an inlay carrier take-up spindle 124 of inlaycarrier take-up spool 132. The supply roll drive 126 supplies both acomputer-controlled unwind resistance and a braking function ontransponder supply roll 128. The take-up roll drive 130, acting on theinlay carrier take-up spindle 124, maintains appropriate tension oninlay carrier 46 to prevent web slippage in the rolamite drive mechanism118 that provides peeling tension for stripping the inlay carrier 46from the programmed RFID transponder 52 at inlay carrier peeler bar 134.

[0055] A transponder position sensor 136 detects when a transponder 52is appropriately placed under the transponder programmer antenna 110.The transponder position sensor 136 is part of the control electronicsshown in FIG. 6, and is used to control the motion of the inlay carrier46.

[0056]FIG. 6 is a schematic, block diagram of principal electroniccomponents of the thermal transfer printer 48 that is shown in FIG. 3.In the illustrated embodiment of the invention, printer 48 includes aprocessor unit 138 with devices attached to a processor bus 140. Theprocessor unit 138 executes a set of program instructions that arereceived from a user via printer I/O port 142 and that are stored inmemory 144. As shown in FIG. 6, processor unit 138 is operativelyelectrically coupled through processor bus 140 to, among other things,platen roller drive 146 which drives platen roller 20; thermal printhead18; transponder programmer 148 which is in turn connected to transponderprogrammer antenna 110; transponder position sensor 136; linear actuator116; supply roll drive 126; rolamite stepping motor 120 which operaterolamite drive mechanism 118; inlay carrier take-up roll drive 130; andtamping solenoid 94.

[0057]FIG. 7 is a flow-chart that illustrates program steps that areexecuted by the processor unit 138 shown in FIG. 6 for each print jobperformed by the thermal transfer printer 48. Programming languages thatare suitable for use in programming print jobs in connection with thepresent invention disclosed in this application include, for example,ZPL II® that is the universal language for printers that aremanufactured by Zebra Technologies Corporation.

[0058] Processor 138 (FIG. 6) first retrieves the parameters of a printjob that a user desires to have done on an on-demand or selective basisfrom memory 144 in process 150. For example, a user may store a set ofinstructions in the memory 144 that will cause printer 48 to print abatch of 100 diecut labels, wherein every other diecut label is to be a“smart label” provided with a programmed RFID transponder 52. It shouldbe understood that all “on-demand” printing jobs are intended to becovered in connection with the present invention to the extent that suchprinting jobs include (in the presently discussed preferred execution ofthe invention) at least one smart label.

[0059] Referring back to FIG. 7, in program step 152, processor unit 138(FIG. 6) determines whether or not a diecut label 14 that is to beprinted is to have a programmed RFID transponder 52 attached to it. Ifnot, then the printed diecut label 26 is formed in process 154. If theentire print job is determined to be completed in program step 156, thenthe program sequence is ended. If the print job is not done, then inprocess 158 both a new diecut label 14 is properly positioned underprinthead 18 for the next printing cycle, and the label format isindexed. Then the processor unit 138 executes instructions to loop toprogram step 152.

[0060] If processor unit 138 determines in program step 152 that an RFIDtransponder is to be attached to a diecut label 14 that is to beprinted, then an RFID transponder 52 is programmed in process 160, andthen is verified as being operable and correctly programmed in process162. If the programmed RFID transponder 52 is correctly verified, thenthe diecut label 14 is printed in process 163 to form printed diecutlabel 26, and then the programmed RFID transponder 52 is attached to theprinted diecut label 26 in process 164 by operation of the value-addingmechanism 50. The processor unit 138 then executes program step 156 tosee if the print job is performed as above. If the print job is notperformed, then the media and label format are indexed in process 158,and the processor unit 138 then loops to program step 152.

[0061] Transponder programming and verification typically occurs priorto printing the media, so that a smart media with a defectivetransponder 52 can be identified by printing “void” on it, for example,rather than the normal label format as, for example, discussed above.The printer 48 then typically ejects the defective smart label, andautomatically repeats the process until a fully functional smart labelwith a properly encoded transponder and the correct label format isproduced. This ensures that the integrity of the batch of labels that auser desires to manufacture in connection with a particular on-demandprint job is accurately made. To wit, if in verification process 162 theprocessor unit 138 determines that the programmed RFID transponder 52 isnot operable, then it may be disposed of directly. Alternatively, asuitable indicia such as, for example, “VOID” is printed in process 163on the diecut label 26, and the inoperable RFID transponder 52 isattached to the “VOID” printed label in process 164 in order to expelthe properly-identified defective transponder 52 from the printer 48.The processor unit 138 loops in processes 160 and 162, etc., to programand verify a new RFID transponder 52, printing an appropriate diecutlabel 26 and attaching them together in process 164 continues until acorrectly printed diecut label 26 with an embedded, verified, programmedRFID transponder 52 is completed. Then the program continues by testingif the print job is complete in program step 156.

[0062] FIGS. 8-10 illustrate one example of a process for attaching aprogrammed RFID transponder 52, or any other suitable value-addingelement, to printed diecut label 26 (step 164 in FIG. 7). The processorunit 138 (FIG. 6) causes the linear actuator 116 to extend and causesthe supply roll drive 126 to unwind the transponder supply spool 128,while rolamite stepping motor 120 and take-up roll drive 130 also unwindan approximately equal amount of inlay carrier 46. This continues untila new, unprogrammed RFID transponder 166 is positioned properly withintransponder position sensor 136.

[0063] In FIG. 9, the processor unit 138 (FIG. 6) now activates thetamping applicator mechanism 56. By applying an electric current tosolenoid coil 94, the magnetic force on iron disc 96 actuates solenoidplunger 68, which, acting through coupler 104, and gas spring plunger97, thus compresses gas spring 98. A nearly constant tamping forceindependent of extension is transmitted by the body of gas spring 98onto drive bracket 104 that extends the flexible bellows 70 and thusplenum 62. This causes the rigid perforated vacuum guide plate 54 topress the adhesive side of printed diecut label 26 against theprogrammed transponder 52, using the rigid guide plate 114 as an anvil.This adheres the programmed RFID transponder 52 to the printed diecutlabel 26.

[0064] Once tamping takes place as, for example, described above, theprocessing unit 138 now causes the linear actuator 116 to retract, whilekeeping the supply roll drive 126 braked so that the new unprogrammedRFID transponder 166 remains fixed under transponder position sensor136. The processor unit 138 activates rolamite stepping motor 120 incoordination with the motion of the linear actuator 116, so thatrolamite stepping motor 120 acts through rolamite drive mechanism 118 totakes up and maintains tension on the excess inlay carrier 46. Tensionon the rolamite drive mechanism is maintained by energizing the take-uproll drive 130, which also causes the excess inlay carrier 46 to windonto the take-up roll spindle 124.

[0065] The retracting motion of the linear actuator 116 on the guideplate 114 together with the tension on inlay carrier 46, aids in peelingthe inlay carrier 46 at the inlay carrier peeler bar 134 from theadhesive layer on the bottom of programmed RFID transponder 52, which isnow adhered to the printed diecut label 26. This peeling processcontinues until the guide plate 114 plate is completely retracted to theposition shown in FIG. 5. The new, unprogrammed RFID transponder 166 isnow properly positioned under transponder programmed antenna 110 forimmediate programming.

[0066] Now that the programmed RFID transponder 52 has been bonded tothe printed diecut label 26, the processor unit 138 deactivates tampingapplicator mechanism 56, which retracts under the force of return spring106.

[0067] In FIG. 10, the diecut label/transponder smart label sandwich(26/52) is advanced by the platen roller 20, slides across the smoothperforated vacuum plate 54 until the next, unprinted diecut label 14 ispositioned under printhead 18 for the next printing cycle. Driving ofthe sandwich (26/52) continues by the driven nip roller 76, andrelamination with the label carrier 12 occurs in nip 72. The productionof the printed and programmed RFID smart labels with embedded programmedRFID transponder 52 is now finished, and the laminated smart label(26/52/12) is delivered at label exit 30. As shown, label carrier 12 mayalso be optionally peeled away from the printed smart label (26/52) in amanner similar to that described in FIG. 1.

[0068] Alternatively, the label carrier 12 delaminated at 32 (FIG. 3)may be removed from the system by, for example, utilization of a take-upmechanism that is similar to 34. In this example, a second supply rollof label carrier 12 may be used for relamination of the label sandwich(26/25/12) at nip 72, and the buffer loop roller 64 eliminated.

[0069] FIGS. 11-15 illustrate an exemplary modification of the thermaltransfer printer 48 (as shown FIG. 3) that is designed for use withtickets, tags, plastics cards, and other stiff media that does notcontain an adhesive layer. This ticket and tag printer 168 comprisesthermal transfer printing mechanism 10; tamping applicator mechanism 56;dispensing mechanism 66 and cutter mechanism 170. The embodiment shownin FIGS. 11-15 also is useful for applying a self-adhesive transponderto a surface of a printed self-adhesive label

[0070] Note that the items that are illustrated in the FIGS. 3-10embodiment but are not specifically shown in FIGS. 11-13 may be presentin an actual product that incorporates all or some of the inventionsdisclosed in the totality of FIGS. 3-14. However, since said unshowncomponents do not have a role in the further exemplary embodimentillustrated in FIGS. 11-14, they are, therefore, are not shown in FIGS.11-14 for purposes of simplicity.

[0071] Referring to FIG. 11, the programmed RFID transponder 52 isitself formed as a transponder label 172 by adhering a diecuttransponder facestock 174 to the top surface of the adhesive-backed,programmed RFID transponder 52 on inlay carrier 46. As stiff media 176often is supplied in continuous form, it may be optionally cut to lengthafter printing. An optional cutter 170, including cutter blades 178, isshown in FIG. 11 between the nip rollers 74, 76 and media exit 30. Theelectrically-operated cutter mechanism 170 is additionally connectedthrough the processor bus 140 (FIG. 6) to processor unit 138 (FIG. 6) aspart of thermal transfer ticket and tag printer 138.

[0072] In FIG. 12, the tamping applicator mechanism 56 is extended in amanner similar to the description for FIG. 9. The processing unit 138(FIG. 6) energizes the solenoid coil 94 of the tamping applicatormechanism 56, which extends the flexible bellows 70 and presses theperforated vacuum guide plate 54 against the transponder label 172. In amanner similar to FIG. 9, a guide plate (not shown) of the dispensingmechanism 66 then is retracted, peeling the inlay carrier 46 away fromthe transponder label 172 at inlay carrier peeler bar 134 (see FIG. 9),thereby leaving the lower adhesive surface of transponder label 172exposed.

[0073] In FIG. 13, when solenoid coil 94 is deenergized, the tampingapplicator mechanism 56 is then fully retracted by spring 106, withtransponder label 172 remaining held against the perforated vacuum guideplate 54 by the vacuum force generated by centrifugal fan 58. Theexposed lower adhesive surface of the transponder label 172 is nowpositioned above the path of stiff media 176.

[0074] The stiff media 176 (which can be a ticket, tag, plastic card,laminated label stock, or the like) is now printed and dispensed forwardby platen roller 20 to the point where the transponder label 170 is tobe placed on it. See FIG. 14. When the printed stiff media 176 is in thecorrect position, tamping applicator mechanism 56 presses thetransponder label 172 onto the printed stiff media 176. Note that theduring the tamping process, the guide plate of dispensing mechanism 66may be optionally extended under the printed stiff media 176 so thatrigid guide plate 114 acts as an anvil for the tamping applicatormechanism 56.

[0075] In FIG. 14, the transponder label/printed stiff media sandwich(172/176) now continues forward through the nip rollers 74 and 76, wherethe transponder label 172 is permanently bonded to the printed stiffmedia 176 by the compression provided by nip rollers 74 and 76. Then, ifdiscrete stiff media 176 are used in forming the transponder/mediasandwich (172/176), the sandwich is ejected through media exit 30.

[0076] In the case of continuous stiff media 176, the stiff mediatrailing the transponder media sandwich (172/176) may be optionally cutto length using the cutter mechanism 170. This is accomplished undercontrol of the print job software, as shown in FIG. 15, by, for example,processor unit 138 activating electrically-controlled cutter blades 178.In that case, the cutoff length of smart ticket or tag exits at 30, andremaining the stiff media 16 is retracted by platen roller 20 to itsposition it under the printhead 18 for the start of the next printingcycle.

[0077]FIG. 15 is a flow-chart that illustrates program steps that areexecuted by the processor unit 138 shown in FIG. 6 for each print jobperformed by the thermal transfer printer 48. Note that many of theprogram steps and processes in FIG. 15 are the same as or similar tothose in the flow chart of FIG. 7. The processor unit 138 firstretrieves the parameters of a print job that a user desires to haveperformed on an on-demand basis from memory 144 in process step 150. Forexample, a user may store a set of instructions in the memory 144 (FIG.6) that will cause ticket and tag printer 168 to print a batch of 21tickets from a roll of continuous stiff media 176, wherein only thefirst ticket is to be a “smart ticket” provided with a programmed RFIDtransponder label 172. It should be understood that all “on-demand”printing jobs are intended to be covered in connection with the presentinvention to the extent that such printing jobs include (in thedescribed preferred execution of the invention) at least one smartticket or tag.

[0078] Referring to FIG. 15, processor unit 138 (FIG. 6) determines inprogram step 180 whether or not a stiff media sample that is to beprinted is to have a programmed RFID transponder label 172 attached toit. If not, then the printed ticket is just formed in process 181. Inprogram step 182, it is determined if the media sample is to be cut.When discrete media such as plastic cards are used, then in process 183the finished media sample is simply ejected at the media exit 30, and anew media sample is positioned under the printhead 18 for the nextprinting cycle.

[0079] When printed continuous stiff media is to be cut, then in process184 the continuous stiff media 176 is positioned to the cut-off pointbetween cutter blades 178 of cutter mechanism 170. The processor unit138 the activates the electrically-operated cutter mechanism 170 to cutoff the printed ticket, tag, smart ticket or smart tag for the stiffmedia supply and deliver it at media exit 30. The continuous stiff mediais then backfed using the platen roller 20 to the start of printposition under printhead 18 for the next print cycle.

[0080] If the entire print job is determined to be completed in step156, then the program sequence is ended. If the print job is not done,then the media print format is indexed in step 185, and then theprocessor unit 138 loops to program step 180.

[0081] If processor unit 138 determines in program step 180 that an RFIDtransponder is to be attached to the next ticket or tag that is to beprinted, then an RFID transponder label 172 is programmed in process160, and then is verified as being operable and correctly programmed inprocess 162. If the programmed RFID transponder label 172 is correctlyverified, then the ticket or tag is printed in process 181, and then theprogrammed RFID transponder label is attached to the printed mediasample by operation of the value-adding mechanism 50 in process 186. Theprocessor unit 138 then executes program step 182 to see if the media isto be cut, taking the appropriate action as described above; thenprogram step 156 to print job is done, also as described above.

[0082] Transponder programming and verification typically occurs priorto printing the media, so that a smart media with a defectivetransponder label 170 can be identified by printing “void” on it in step187 rather than the normal media format 181. The ticket or tag printer168 then typically ejects the defective smart ticket or tag at mediaexit 30, and automatically repeats processes 160 and 162, etc., until afully-functional smart ticket or tag with a properly encoded transponderand the correct printed media format is produced, in a manner similar tothat as described in FIG. 7.

[0083] Additionally, a variation of the embodiment shown in FIGS. 11-15may be used to actually form transponders by printing an conductiveantenna on the media sample and then attaching labels comprised of RFIDintegrated circuits with electrical contacts to that antenna (forexample the Motorola BiStatix™ “interposer”; and those made by Marconiusing an Intermec Intellitag® 900 MHz or 2.45 GHz RFID integratedcircuit).

[0084] For example, in FIG. 16A a BiStatix label 190 based on MotorolaBiStatix™ integrated circuit 191 is formed on transparent nonconductivelabel stock 192 by first forming two conductive mounting pads 193 andbonding them to two antenna contacts on Motorola BiStatix™ integratedcircuit 191. These BiStatix labels 190 in roll form are used astransponder supply roll 128 in ticket and tag printer 168. During theprinting process, by proper choice of thermal transfer ribbon 16 andnonconductive media 194, two printed conductive carbon antenna panels195 can be formed on the ticket or tag. The value-adding mechanism 50can be used to attach the conductive mounting pads 193 of each BiStatixlabel 190 to the two printed conductive carbon antenna panels 195 toform a complete RFID transponder, as shown in FIG. 16B. By properplacement of the transponder programmer antenna 110, theelectrostatic-coupled RFID transponder so formed then may be programmed.

[0085] More conventional magnetically- or electromagnetically-coupledtransponders also may be formed this way. In FIG. 16C, a 2.45 GHz RFIDIntellitag label 196 based on an Intermec Intellitag® integrated circuit197 is formed on transparent nonconductive label stock 192 by with twometal contacts 198 bonded to the two antenna contacts on an IntermecIntellitag® integrated circuit 197. A rolls of these Intellitag labels196 is used as transponder supply roll 128 in ticket and tag printer168. During the printing process, by proper choice of thermal transferribbon 16 and nonconductive media 194, a 2.45 GHz conductive silver inkfolded dipole antenna 199 can be formed. The value-adding mechanism 50can be used to attach the two metal contacts 198 of the Intellitag label196 to the ends of the conductive silver ink folded dipole antennapanels 199 to form a complete RFID transponder, as shown in FIG. 16D. Byproper placement of the transponder programmer antenna 110, theelectromagnetically-coupled transponder so formed then may beprogrammed.

[0086] The present invention provides a number of distinct advantages,either individually and/or collectively. Such advantages include, forexample, the following.

[0087] 1. The ability to selectively add an RFID transponder to aconventional on-demand printed media sample under program control,thereby converting a conventional label into a “smart” RFID enhancedmedia sample;

[0088] 2. The ability to selectively create an RFID transponder using aprinted antenna and applied RFID integrated circuit on a conventionalon-demand printed media sample under program control, thereby convertinga conventional label into a “smart” RFID enhanced media sample;

[0089] 3. The ability to provide a single label, ticket tag or plasticcard printer that can produce, on-demand, either conventional or “smart”RFID media using the same conventional label, ticket, tag stock orcards; and

[0090] 4. The elimination of the need for pre-converted RFID smartmedia, thereby removing the attendant cost of these items beingspecially produced by a label converter and inventoried by the user.

[0091] Additional advantages of the present invention include thefollowing.

[0092] 5. The impact of the “lumpy” transponder on print quality inproducing a smart media sample is eliminated because printing of themedia is done before the RFID transponder is embedded in or adhered ontothe final media sample;

[0093] 6. The ability to design an add-on option to a conventionallabel, ticket, tag or plastic card printer to enhance it to producesmart labels, tickets, tags or plastic cards on an as-needed basis;

[0094] 7. The ability to cause a single printer to produce eitherconventional or smart media using conventional media supplies as a basis(as the smart media can be produced only when needed using the on-demandbasis label format software control);

[0095] 8. The removal of the need for a label converter to providespecial rolls of smart labels for on-demand printers, with the attendantextra costs of making and inventorying special smart label stock.

[0096] 9. The removal of the need for the user to have a separatethermal transfer printer to produce smart labels;

[0097] 10. The elimination of user dependence on smart label converters,thereby allowing the user to use their existing converter;

[0098] 11. The allowance of designs that permit all printers in aproduct line to do, on an on-demand, programmed-controlled basis, bothconventional labels, tickets, tags and cards, and also smart labels,tickets, tags and cards; and

[0099] 12. The reduction of the cost overhead and complexity barriers ofadding smart label capability to an existing conventional labelingprocess. Still further advantages and benefits follow.

[0100] As described above in the list of advantages, the invention makespossible a truly on demand, custom configuration of any selected one, orall, of the media to have an RFID transponder of a particular type orcapability, programmed with particular data, and preprinted orpost-printed or otherwise processed. This implies that end users do nothave to install a variety of printers or other systems in order to takecare of the requirements of various customers or applications. Sinceentire rolls of unprinted smart labels (each possibly having a differentmaterial, adhesive, label form factor or type of transponder) do nothave to be stocked, the cost savings are significant. The capital andmaintenance costs of single purpose lines or machines is avoided. Sincethe entire process is under computer program control, errors whichinevitably result in manual changeover from plain labels to RFID labels,for example, is eliminated. One machine or system can now handle allneeds.

[0101] In a more general sense, the present invention concerns a methodof configuring on demand a series of labels, tickets, tags, cards orother media. The method comprises feeding a series of media which may bealike or different, and, on demand, selectively applying, inserting, orotherwise associating with certain media but not with other media in theseries one or more discrete, value-adding elements. In the describedpreferred embodiment the elements are RFID transponders, however, aswill be described, other value-adding elements may be associated withthe selected media.

[0102] A third embodiment illustrating the more general nature of theon-demand configuration process for media is the application shown inFIGS. 17-19. With the advent of “mass customization” marketing, and thedevelopments in prospect-specific data resources available today, it ispossible to narrowly target a very specific group of prospects, aboutwhich much is known concerning their identification, attributes,predilections, purchasing habits and other personal characteristics. Thepresent invention gives total flexibility in appealing to particularpurchasing interests and other characteristics of a particular set ofprospects or past customers.

[0103] In this illustrative hypothetical application, Travel CardCompany wishes to send custom configured promotional media to a selectedcustomer base. Its customers consist of three classes: Green, Gold andPlatinum card members. Green Members are occasional travelers, mostlyfor vacations, and comprise the lowest category of card usage. GoldMembers use the card frequently, primarily for business, but often takevacations abroad, and represent a smaller population with much higherusage than Green Members, and as a class represent most of the traveldollars spent with Travel Card Company. Platinum Members are a muchsmaller class, with an average annual card usage five times that of GoldMembers, mostly spent on international travel, using first class airfareand luxury hotels and restaurants; they often mix business and pleasuretravel, and they often travel with spouses or “significant others.” Theyare highly desirable customers for the luxury class travel andmerchandise companies.

[0104] The promotional media is here a custom postcard set 200 as shownin postcard set front 202 and postcard set reverse side 204 in FIGS. 17Aand 17B, comprised of customer addressed postcard with detachable returnpostcard. The postcard set front side 202 is intended to be on-demandprinted with customer-specific mailing address 206 and selectedpromotional travel offerings incorporating value-adding elements. Thereverse side 204 of postcard set 200 is entirely preprinted with fixedinformation: The postcard set reverse side 204 of the customer addressedpost card is printed with pictorial information 208 about luxury cruiseA and pictorial information 210 about luxury cruise B; the postcard setreverse side 204 of customer return post card is printed with TravelCard Company return address 212 and business reply postage 214. Postcard set 200 is intended to be machine folded and sealed so that thecustomer address 206 and business postage franking 216 is visible oninitial mailing.

[0105] The postcard set front side 202 of is on-demand printed withcustomer specific information and promotional offers, including certainvalue-adding elements from FIG. 18 that are placed in areas 218 and 220depending on the promotional offer being made to the specific customeridentified in customer address 206. The postcard set front side 202 ofreturn postcard has luxury cruise A description 222 with associatedinformation request area 224; also luxury cruise B description 226 withassociated information request area 228. In addition, for Gold andPlatinum Members, there are special on-demand printed promotional areasthat are not printed unless special offers are being made; this includespromotional area 230 with customer-markable response areas 232 and 234,associated information request area 236, and a reserved area 238.

[0106] In FIG. 18, four value-adding elements 240 through 246 are shown.Repositionable 2-class cruise upgrade coupon 240 intended to be offeredto Green Members only; repositionable 3-class cruise upgrade coupon 242is intended to be offered only to Gold and Platinum Members; theappropriate coupon is to be placed on customer address postcard incruise upgrade offer area 218. Permanently attached RFID transponderlabel 244 is to be placed in Platinum Member promotional reserved area238 on postcard set reverse side 204 (see FIG. 17B) of all mailings toPlatinum Members. It carries in the transponder memory the PlatinumMember-specific address, travel history and card usage information 248.It is preprinted with an offer of free global Internet E-mail service byan Internet Service Provider associated with Travel Card Company whichalso advertises on-line only luxury merchandise. When a Platinum Memberaccepts the free E-mail offer, the return postcard is given to theInternet Service Provider and the information stored in the memory ofthe RFID transponder label 244 is read wirelessly and used toautomatically set up the Platinum Member's global Email account. In caseof transponder failure, the key customer information, namely name andcard number, are also on-demand printed in customer name and card numberfield 250.

[0107] Repositionable free flight coupon 246 contains an offer fromUrban Legends Helicopter Service for a free helicopter flight form themain airport to a downtown heliport in New York City, Chicago, Paris orTokyo. It is intended to be offered only to those Gold and PlatinumMembers which also stay more than a total of fifteen nights each year inthe luxury downtown hotels in any or all of those four cities. Whenappropriate for use with a given card member, it is placed in specialoffer area 220 on customer address postcard.

[0108] In accordance with certain aspects of the production process tobe described in detail below, an on-demand printed postcard set isproduced for each Green, Gold or Platinum Member with selectedvalue-adding elements from FIG. 18 to be placed as described abovedepending on the member's card color and travel history. When receivedby each member, if so interested, the member takes specific actions withrespect to the repositioning any value-added coupons present and markingthe customer response areas 232 and 234 (if present) to accept or rejectthe associated promotional offers. The interested member then mails thepostage-paid return card to Travel Services Company to implement therequested promotional offers.

[0109] Returning to FIG. 17, if the member is interested in receivingthe information about luxury cruise A, then the offered value-addingcoupon (either 240 or 242) in cruise upgrade offer area 218 is removedand placed in information request area 224. Similarly, information aboutluxury cruise B may be requested by removing said repositionable cruiseupgrade coupon from offer area 218 and placing it in information requestarea 228. Should a Platinum Member decide to accepted the free globalE-mail service offered by the preprint on RFID transponder label 244, hechecks the “Yes” box in custom-printed response area 232 (printed onlywhen RFID transponder label 244 is also attached in reserved are 238).Should the selected Gold and Platinum Members receiving the special freeflight offer coupon 248 from Urban Legend Helicopters decide to acceptit, said member removes the coupon from special area 220 and places itin special area 238, and checks the box in custom printed area 236 forthe city in which the member would like the free flight.

[0110]FIG. 19 is a top schematic view of one example of a three-stageproduction process embodying exemplary aspects of the invention in threedifferent forms that may be used to prepare the finished postcard sets.A supply of postcard stock 300 which is preprinted on the reverse sideof each postcard set 200 with fields 208, 210, 212, 214 and 214 (seeFIG. 17), and possibly preprinted only on the front side with businesspostage franking 216 (all though forms of this may also be on-demandprinted). Postcard stock 300 passes through postcard printer 302, whichcontains a variation of the second invention embodiment 168 usingexternally preprogrammed transponder labels. This postcard printer 302is driven through connection 304 to factory controller 306, which inturn is connected through local area network 308 to main computer 310which includes processing program 312 and card member database 314.Certain file information from each entry in card member database 314 isselected by processing program 312 and is transferred over local areanetwork 308 to factory controller 306 for use by factory control program316 to direct the production operations in the preparation of eachcorresponding postcard set 200.

[0111] Typically, the member files in card member data base 314 are insequential order with respect to card number, but random by membershipcolor as this may change during the life of a card member account. Foreach Platinum Member file encountered, transponder label printer 318,which contains the first invention embodiment described above, isdirected by factory controller 306 over connection 320 to prepare anRFID transponder label 244. Using diecut label supply 322 andself-adhesive RFID transponder supply 324, the transponder label printer318 produces a sequential transponder label strip 326 of programmed RFIDtransponder labels 244, each of which has been preprinted with thePlatinum Member's name and card number, and embeds an RFID transponderencoded with relevant card member information from database 314. Thissequential transponder label strip 326 of RFID transponder labels 244 isused as the RFID transponder label supply for postcard printer 302.

[0112] The Stage 1 production operation is performed by postcard printer302, and includes all the on-demand printing operations. As postcardprinter 302 is directed to initiate preparation of a postcard set 200for each card member, the required card member information istransferred to it over connection 304. If information for a Green orGold Member is found, then just the appropriate on-demand printedcustomer mailing address 206 on the front side of card, and luxury A andB cruise information 222 and 226, respectively, are printed on thepostcard set front side 202 of return mail card (see FIG. 17). If a Goldor Platinum Member is found to qualify for the free flight coupon, thenoffer customer-markable response area 232 is also printed. For allPlatinum Members fields 206, 222, and 226 are printed the same as for aGold Member, and the customer-markable response area 234 to speciallifetime E-mail offer is also printed. It is first verified that thecorresponding RFID transponder label 244 is in position for placement;then said RFID transponder label 244 is placed in reserved field 238. Aschematic example of first Green Member postcard set 328 and firstPlatinum Member postcard set 330 as outputs of Stage 1 production areshown in FIG. 19.

[0113] In Stage 2 of the production process, additional value-addingprocesses incorporating the invention are used to complete the customconfiguration of the postcard set media by the addition of one or moreof selected value-added elements shown in FIG. 18. First additionalvalue-adding process 332 selectively adds 2-class cruise upgrade coupon240 from first coupon supply 334 to postcard set 200 when so directed byproduction controller 306 over connection 336. Second additionalvalue-adding process 338 selectively adds 3-class cruise upgrade coupon242 from second coupon supply 340 to postcard set 200 when so directedby production controller 306 over connection 342. Third additionalvalue-adding process 344 selectively adds free flight coupon 246 fromthird coupon supply 346 to postcard set 200 when so directed byproduction controller 306 over connection 348.

[0114] Exemplary output from the Stage 2 are shown as custom configuredpostcard media 350, 352, 354 and 356. Second Platinum Member postcardset 350 was custom configured with free flight coupon 246 using thirdadditional value-adding process 344; 3-class cruise upgrade coupon 242added by second additional value-adding process 338; and RFIDtransponder label 244 as configured by the first invention embodiment intransponder label printer 320 and placed by second invention embodimentin postcard printer 302. First Gold Member postcard set 352 was customconfigured with only 3-class cruise upgrade coupon 242 added in secondadditional value-adding process 338. Second Green Member postcard set354 was configured for a Green Member receiving only 3-class cruiseupgrade coupon 240 added in first additional value-adding process 332.Second Gold member postcard set 356 is custom configured with cruiseupgrade coupon 242 from second additional value-added process 338 andfree flight coupon 246 from third additional value-adding process 344.

[0115] In Stage 3 of the production process of FIG. 19,sheeter-folder-sealer process 358 is used to prepare the customconfigured postcard media for mailing, under control of productioncontroller 306 using connection 360. The continuous postcard media iscut part into individual postcard sets 200, folded and sealed to exposethe front of the customer address postcard set front side 202. Anexample of Stage 3 output, namely a finished postcard set 362 is shownbeing ejected from sheeter-folder-sealer 358 on to the stack ofcompleted custom-configured postcard media 364.

[0116] A number of alternatives of the FIGS. 17-19 method and system arecontemplated by the present invention. For example, in one variantcoupons 240, 242, and/or 246 also have RFID transponders. Thetransponders in these value-adding elements may be programmed with thesame data as described above with respect to transponder 244. What isunique in this variant is that the element which is peeled off andtransferred to another part of the media (which could also be to anotherseparate media) is or has embodied therein a memory containing usefulinformation which can be accessed wirelessly by the organizer of thepromotion or another involved party.

[0117] Alternatively, rather than an RFID transponder of the type havinga memory, a chipless RFID transponder may be substituted. For example,rather than a transponder such as shown at 244, in space 238 on card set200 a resonant series of conductive lines may be printed on the card. Ora variety of other chipless RFID technologies may be employed.Integrated circuit labels, of a type similar to those shown in FIG. 16,may also be used with printed antennae to form RFID transponders insitu.

[0118] In accordance with exemplary aspects of the present invention, asdescribed in FIGS. 17-19, on demand a mailer is being sent which has thefollowing attributes:

[0119] 1) various personalized on demand printings on the media directedto appeal to known interests of the target prospect;

[0120] 2) various targeted coupons or other value-adding elements placedon demand on the media;

[0121] 3) RFID transponders containing target specific data which willbe used in after processing the card when returned;

[0122] 4) on demand printing on the transponders which is tied to thetarget and the stored information;

[0123] 5) plural value-adding elements which not only relate to thetarget prospect, but to each other as well, to form a coordinated,prospect-specific appeal;

[0124] 6) an action response item (the transferred coupons) promptingthe prospect to take action which is not just a generic “YES I WANT TOBUY” token, but a response item which is personalized for the particularprospect.

[0125] In short, the card may have as many as half dozen or more ondemand printings or value-adding elements which are coordinated todevelop a powerful personalized and integrated sales appeal.

[0126] In yet another execution of certain exemplary aspects of theprinciples of the invention, a transponder 52 may be programmed withinstructions which control subsequent processes such as the applicationof another value-adding element on the same media. For example, in avariant of the FIGS. 17-19 embodiment wherein the value-adding processes332, 338 and/or 344 are distributed and not under the control ofcontroller 306, RFID transponder label 244 could be programmed withinstructions which would be read as part of the value-adding processesto determine the type, content, or other characteristic of avalue-adding element to be added to the media containing the transponderlabel 244. Alternatively, for example, address data stored in the label244 could be read at a postage metering station to determine the correctpostage.

[0127] Thus, the embodiment of FIGS. 17-19 illustrates certain exemplaryfeatures of the present invention as a method of configuring on demand aseries of labels, tickets, tags, plastic cards, postcards or other mediaby selectively applying, inserting, or otherwise associating withcertain media—but not with other media—in the series one or morediscrete, value-adding elements. And, preferably, in a coordinatedintegration therewith, the application of one or more printings on themedia and/or the value-adding elements to provide further flexibility inthe presentation of information to end users and other.

[0128] Referring to FIG. 20, one embodiment of a transponder applicatormechanism 300 is illustrated that selectively and on demand, underprogram control, encodes an RFID transponder, and attaches the same toan adhesive backed previously printed diecut label 26. The transponderapplicator mechanism 300 may be integrated with existing thermaltransfer printing mechanism 10, or it may be attached to a thermalprinter as an optional accessory.

[0129] In the embodiment of the invention illustrated in FIG. 20, theprinted diecut label 26 is removed from its label carrier 12 by theaction of peeler bar 32 and label carrier take-up mechanism 34. Duringits forward motion that is driven by platen roller 20, the printedsurface of the printed diecut label 26 maintains a substantiallystraight path towards media exit 30 along a perforated vacuum guideplate 302. The light vacuum force 304, that is generated by acentrifugal blower 306 that expels air 308 from a closed plenum 310,controls the path of, but does not impede the motion of, diecut label26.

[0130] When formation and encoding of a smart label is desired, then,prior to printing the diecut label 26, an RFID transponder 312 is in aposition under antenna 314. Antenna 314 encodes the RFID transponder312, and verifies the same using radio signal 316 in the mannerdescribed in this application. In the illustrated embodiment, thetransponders are adhesive backed, and are supplied diecut from an inlaycarrier 318 by inlay supply mechanism 320.

[0131] Referring to FIG. 21, when the leading edge of the next diecutlabel 14 is in position under the printhead 18, the motion of the platenroller 20 and label carrier take-up mechanism 34 stops. Also, forwardmotion of the printed diecut label 26 continues now to be driven by thesiliconized drive roller 322, which is typically operationally coupledto the drive of platen roller 20, but runs at a slightly faster surfacespeed. It presses lightly against the adhesive side of printed diecutlabel 26 and against spring loaded nip roller 324.

[0132] Assuming that correct encoding and verification has taken place,when the printed diecut label 26 is at the correct position in itsforward travel, the encoded RFID transponder 312 is now moved in forwardby the action of inlay carrier take-up mechanism 326 on inlay carrier318. As the transponder 312 reaches the top of its path over roller 328,the linear actuator 330 now advances small roller 328, which presses theleading edge of encoded transponder 312 against the adhesive side ofprinted diecut 26.

[0133] Both the inlay carrier 318 and the printed diecut label 26 arenow driven forward at the same surface speed, so that the encoded RFIDtransponder 312 is peeled from the inlay carrier 318 as it passes overthe small roller 328, as shown in FIG. 22. Once the encoded RFIDtransponder 312 is completely peeled from the inlay carrier 318, thenthe linear actuator 330 retracts, and the next unencoded transponder 332in now in position under antenna 314 for use in the next smart labeldispensing cycle.

[0134] Referring to FIG. 23, forward motion continues until the peeledprinted diecut label and encoded RFID transponder sandwich (26/312) indelivered at media exit 30. The pressure of the nip formed bysiliconized drive roller 322 acting on the sandwich against springloaded nip roller 324 permanently bonds the peeled printed diecutlabel—encoded RFID transponder sandwich (26/312).

[0135] Transponders which fail to verify may be either (1) attached to“void” printed labels as described above, (2) recaptured while still onthe inlay carrier 318 by the inlay carrier take-up mechanism 326, or (3)dispensed internally into a waste bin. The latter 2 methods avoidwasting a label to eliminate a bad transponder.

[0136] A still further embodiment for continuous linerless media usingactive adhesives (i.e., where there is no diecut label carrier 12) isshown in FIG. 24. Here, platen roller 20 and drive roller 322 are bothsiliconized to prevent adherence of the label and transponder adhesiveto these rollers. The continuous linerless label stock 350 is printedand an encode RFID transponder 312 attached in a manner similar to theabove embodiment. However, once a completed label is dispensed to mediaexit 30, as shown, then an optional electrically activated cutterassembly 352 is used to shear the finished linerless label 354 with orwithout attached encoded RFID transponder 312. The continuous linerlesslabel stock 350 is then retracted to its initial printing position underprinthead 18.

[0137] When an inactivated adhesive is used (such as an AppletonActifuse liner material), then an optional retractable activatingmechanism 356 may be used to activate the adhesive along the length ofthe finished linerless label 354 retracted for the length of the excessmedia, which must be dispensed to bring the finished linerless label 354to the cut off point. Otherwise, the embodiment functions as withstandard linerless material as described above.

[0138] From the foregoing, it will also be observed that numerousmodifications and variations can be effectuated by those skilled in theart without departing from the true spirit and scope of the novelconcepts of the present invention. It is to be understood that nolimitation with respect to the specific embodiments illustrated isintended or should be inferred. The disclosure is intended to cover bythe appended claims all such modifications as fall within the scope ofthe claims when the claims are properly interpreted.

We claim:
 1. A media printer, comprising in combination: means formoving a plurality of media samples from a supply of media samples;means for printing information on at least selected ones of said mediasamples; and means for attaching a value-adding device to only selectedones, but not all, of said media samples.
 2. The media printer of claim1 wherein said value-adding devices comprise radio frequencyidentification transponders.
 3. The media printer of claim 2 furthercomprising means for determining whether said radio frequencyidentification transponders are defective or misprogrammed.
 4. The mediaprinter of claim 3 further comprising means for causing a failureindicia to be printed on a surface of each one of said media samples towhich a defective or misprogrammed radio frequency identificationtransponder is attached.
 5. The media printer of claim 1 wherein aplurality of value-adding devices are attached to at least one of saidplurality of media samples.
 6. The media printer of claim 1 wherein saidmedia samples are selected from a group consisting of labels, tickets,tags, and cards.
 7. A media printer, comprising in combination: a mediasupply and a media exit; a generally continuous web that operablyinterconnects said media supply and said media exit so that a pluralityof media samples are moved from said media supply to said media exitduring operation; a printhead that is mounted in operative relation tosaid generally continuous web to print information on selected portionsof a first surface of each one of said media samples; and an applicatormechanism that is mounted in operative relation to said generallycontinuous web to attach a value-adding device to a second surface ofselected ones of said media samples after information has been printedon the first surface of said selected ones of said media samples by saidprinthead.
 8. The media printer of claim 7 wherein said value-addingdevices comprise radio frequency identification integrated circuitsadopted to make contact with an antenna structure on said media samplesto form radio frequency identification transponders.
 9. The mediaprinter of claim 7 wherein said value-adding devices comprise radiofrequency identification transponders.
 10. The media printer of claim 9further comprising a verification mechanism that is operably disposedwith respect to said generally continuous web to verify the operabilityof at least some of said radio frequency identification transponders.11. The media printer of claim 10 wherein said verification mechanismcauses failure indicia to b e printed on the first surface of each oneof said media samples to which an inoperable radio frequencyidentification transponder is attached.
 12. The media printer of claim 7wherein a value-adding device is attached to less than all of saidplurality of said media samples.
 13. The media printer of claim 7wherein said media samples are selected from a group consisting oflabels, tickets, tags, and cards.
 14. A method for manufacturing aprinted media, comprising the steps of: moving a plurality of mediasamples from a media supply to a media exit; printing information onselected media samples; and attaching a value-adding device to saidselected ones of said media samples after information has been printedon the first surface of said selected ones of said media samples. 15.The method of claim 14 wherein said value-adding devices comprise radiofrequency identification integrated circuits adopted to make contactwith an antenna structure on said media samples to form radio frequencyidentification transponders.
 16. The method of claim 14 wherein saidvalue-adding devices comprise radio frequency identificationtransponders.
 17. The method of claim 14 further comprising the step ofverifying that at least some of said radio frequency identificationtransponders are operable.
 18. The method of claim 17 further comprisingthe step of causing failure indicia to be printed on the first surfaceof each one of said media samples to which an inoperable, ormisprogrammed radio frequency identification transponder is attached.19. The method of claim 14 wherein a value-adding device is attached toless than all of said plurality of said media samples.
 20. The method ofclaim 14 wherein said media samples are selected from a group consistingof labels, tickets, tags, and cards.
 21. A device for use in connectionwith a thermal transfer printer that includes first web means for movinga plurality of media samples from a supply of media samples as well as aprinthead that prints information on a first surface of said pluralityof media samples, said device comprising: a second web means fortemporarily removing the plurality of media samples from said first webmeans; and means for attaching a value-adding device to a second surfaceof selected ones of said media samples after information has beenprinted on the first surface of said selected ones of said mediasamples.
 22. The device of claim 21 wherein said value-adding devicescomprise radio frequency identification integrated circuits adopted tomake contact with an antenna structure on said media samples to formradio frequency identification transponders.
 23. The device of claim 21wherein said value-adding devices comprise radio frequencyidentification transponders.
 24. The device of claim 23 furthercomprising means for verifying that at least some of said radiofrequency identification transponders are operable.
 25. The device ofclaim 24 further comprising means for causing a failure indicia to beprinted on the first surface of each one of said media samples to whichan inoperable radio frequency identification transponder is attached.26. The device of claim 21 wherein a value-adding device is attached toless than all of said plurality of media samples.
 27. The device ofclaim 21 wherein said media samples are selected from a group consistingof labels, tickets, tags, and cards.
 28. A device for use in connectionwith a thermal transfer printer that includes a first web that allows aplurality of media samples to be moved from a supply of media samples aswell as a printhead that prints information on a first surface of saidplurality of media samples, said device comprising: a second web thattemporarily removes the plurality of media samples from said first web;and an attachment mechanism that attaches a value-adding device to asecond surface of selected ones of said media samples after informationhas been printed on the first surface of said selected ones of saidmedia samples.
 29. The device of claim 28 wherein said value-addingdevices comprise radio frequency identification integrated circuitsadopted to make contact with an antenna structure on said media samplesto form radio frequency identification transponders.
 30. The device ofclaim 28 wherein said value-adding devices comprise radio frequencyidentification transponders.
 31. The device of claim 30 furthercomprising means for verifying that at least some of said radiofrequency identification transponders are operable.
 32. The device ofclaim 31 further comprising means for causing a failure indicia to beprinted on the first surface of each one of said media samples to whichan inoperable radio frequency identification transponder is attached.33. The device of claim 28 wherein a value-adding device is attached toless than all of said plurality of media samples.
 34. The device ofclaim 28 wherein said media samples are selected from a group consistingof labels, tickets, tags, and cards.
 35. A method, comprising the stepsof: providing a series of media samples which have a non-existent orpredetermined capability of responding wirelessly to a wirelessinterrogation signal or electromagnetic field; and introducing acapability, or modifying an existing predetermined capability, of onlyselected ones, but not all, said series of media samples of respondingto a wireless interrogation signal or electromagnetic field.
 36. Themethod of claim 35 wherein said value-adding devices comprise radiofrequency identification integrated circuits adopted to make contactwith an antenna structure on said media samples to form radio frequencyidentification transponders.
 37. The method of claim 35 wherein saidintroducing or modifying step comprises inserting, applying, forming orotherwise associating an RFID transponder with only said selected onesof said series of media samples.
 38. The method of claim 37 wherein saidRFID transponder is selected from a group consisting of a chiplesstransponder, a passive transponder, and an active transponder.
 39. Themethod of claim 36 wherein said media samples are selected from a groupconsisting of labels, tickets, tags, and cards.
 40. The method of claim35 including introducing or modifying an electrical characteristic ofonly said selected ones of said series of media samples.
 41. The methodof claim 40 wherein said selected ones of said series of media sampleshave a preformed characteristic impedance, and wherein said introducingor modifying step comprises altering said preformed characteristicimpedance.
 42. The method of claim 41 wherein said preformedcharacteristic impedance becomes a resonant structure by attachment of avalue-adding device to form a passive transponder.
 43. The method ofclaim 41 wherein said preformed characteristic impedance becomes aresonant structure by attachment of a value-adding device to form achipless transponder.
 44. The method of claim 41 wherein said preformedcharacteristic impedance becomes a resonant structure by attachment of avalue-adding device to form an active transponder.
 45. The method ofclaim 35 wherein said introducing or modifying step comprises forming orchanging a resonant structure on the selected media.
 46. The method ofclaim 45 wherein said forming or changing step comprises depositing oraltering a pattern of electrically conductive lines or patterns on themedia.
 47. A method of configuring on demand a series of labels,tickets, tags, cards or other media, comprising: moving a series of likeor unlike media; and on demand, selectively applying, inserting, orotherwise associating with selected ones of said series of like orunlike media, a discrete, value-adding element.
 48. The method of claim47 wherein said value-adding element comprises an RFID transponder orother wireless transponder.
 49. The method of claim 48 wherein saidelement is a radio frequency identification integrated circuit adoptedto make contact with an antenna structure on said media to form a radiofrequency identification transponder.
 50. The method of claim 48 furthercomprising the step of communicating with said transponder before saidassociating step.
 51. The method of claim 50 wherein said RFIDtransponder is programmed with process control instructions.
 52. Themethod of claim 50 wherein said step of communicating includes the stepsof testing, (i) identifying, or discerning a characteristic of thetransponder, and (ii) reading information stored in said transponder orwriting information into said transponder.
 53. The method of claim 47further comprising the step of processing said media before saidassociating.
 54. The method of claim 53 wherein said step of processingincludes printing on said media.
 55. The method of claim 54 wherein saidstep of printing exhibits a result of said communication with saidtransponder.
 56. The method of claim 55 wherein said printing indicatesa defect or another characteristic or attribute of said transponder. 57.The method of claim 55 wherein said printing exhibits information readfrom or stored in said transponder.
 58. The method of claim 47 includingprocessing said media after said associating.
 59. The method of claim 58wherein said processing includes printing on said media.
 60. The methodof claim 59 wherein said step of printing comprises direct thermalprinting, laser printing, ink jet printing or thermal transfer printing.61. The method of claim 47 wherein said value-adding element has anadhesive on a surface and is laminated on a carrier, and wherein saidstep of associating includes removing said carrier to expose saidadhesive surface.
 63. The method of claim 61 wherein said value-addingelement is pressed against said media after said step of removing tocause adherence therebetween.
 63. The method of claim 62 wherein saidvalue-adding element is tamped against said media pressing.
 64. Themethod of claim 63 wherein said tamping comprises: providing afast-acting solenoid; providing a gas spring that is driven by saidsolenoid; and utilizing a pressure-applying mechanism that is coupled tosaid gas spring and that defines a surface to press together said mediaand said element, said gas spring damping the fast action of saidsolenoid.
 65. The method of claim 47 further comprising the step ofplacing said media on a carrier after said value-adding element isassociated, creating a carrier-element-media laminate.
 66. The method ofclaim 65 wherein said carrier is the same carrier employed to carry saidmedia before said associating step.
 67. The method of claim 65 furthercomprising the step of passing said carrier-element-media laminatethrough pinch rollers.
 68. The method of claim 65 further comprising thestep of affixing said carrier-element-media laminate to an object, orremoving the carrier and affixing the resulting element-media laminateto an object.
 69. The method of claim 47 wherein said media is moved ina first direction, and wherein said value-adding element is moved intoposition for application in a second direction that is different fromsaid first direction.
 70. The method of claim 69 wherein said seconddirection is transverse to said first direction.
 71. The method of claim47 further comprising the step of applying multiple value-addingelements to a single discrete media.
 72. The method of claim 71 whereinat least one of said multiple value-adding elements is an RFIDtransponder or other wireless transponder.
 73. The method of claim 72wherein at least one of said elements is a radio frequencyidentification integrated circuit adopted to make contact with anantenna structure on said media to form a radio frequency identificationtransponder.
 74. The method of claim 71 wherein each of said multiplevalue-adding elements comprises an RFID transponder or other wirelesstransponder.
 75. The method of claim 71 further comprising the step ofselectively printing said single discrete media.
 76. The method of claim71 wherein said multiple value-adding elements are applied in sequence.77. The method of claim 71 wherein said multiple value-adding elementsare applied successively at a single station or at multiple stations.78. The method of claim 47 wherein said moving and said otherwiseassociating steps are performed under computer program control.
 79. Themethod of claim 47 wherein said media are intermittently moved, and arestopped during said applying step.
 80. The method of claim 47 furthercomprising the step of moving said value-adding elements into a positionon a dispensing device which is retracted after a value-adding elementis applied to a media.
 81. The method of claim 47 wherein saidvalue-adding element comprises a promotional device or peel-off label.82. The method of claim 47 wherein said media includes printedinformation on a surface thereof.
 83. The method of claim 82 whereinsaid printed information indicates whether said value-adding element isdefective, inoperative, or has another characteristic or attribute. 84.The method of claim 82 wherein said printed information indicateswhether the media or element has failed a test.
 85. The article of claim84 wherein said printed information includes test results or a date ortime stamp.
 86. The method of claim 47 further comprising the step ofprinting said media after the step of associating a value-adding elementwith the selected media.
 87. The method of claim 47 wherein said step ofassociating is performed under computer program control.
 88. The methodof claim 47 further comprising the step of associating a plurality ofvalue-adding elements with a single selected media.
 89. The method ofclaim 47 further comprising the step of associating value-addingelements with different characteristics or data with selected differentmedia.
 90. The method of claim 47 wherein said media are moved on anadhesive-backed carrier, and wherein said step of associating includesdelaminating said carrier from a selected media, and attaching aselected value-adding element to the exposed adhesive surface of saidmedia.
 91. The method of claim 78 wherein said steps of associatingincludes supporting a peeled media with vacuum, bringing said selectedvalue-adding element into position adjacent the supported media, andpressing the media and element together.
 92. The method of claim 91wherein said selected value-adding element is tamped into position. 93.The method of claim 91 wherein the selected media and said selectedvalue-adding element are relaminated after being pressed together. 94.The method of claim 90 wherein said selected media is relaminated aftersaid selected value-adding element is attached.
 95. The method of claim47 wherein said like or unlike media have different characteristics. 96.The method of claim 47 wherein said associated value-adding elementshave different characteristics.
 97. The method of claim 47 wherein,under computer program control and on demand, individual media havingselected characteristics are custom configured by causing one or morevalue-adding elements having chosen characteristics to be associatedwith said individual media.
 98. The method of claim 97 wherein saidindividual media is further customized on demand by processing saidindividual media under said computer program control.
 99. The method ofclaim 98 wherein said processing step includes printing on saidindividual media.
 100. The method of claim 99 wherein said step ofprinting on said individual media is related to a value-added elementassociated with each one of said individual media.
 101. The method ofclaim 97 wherein said individual media is further customized on demandby processing of the selected value-adding element.
 102. The method ofclaim 101 wherein said element is an RFID transponder, and wherein saidprocessing of said element includes programming or reprogramming thetransponder.
 103. The method of claim 47 wherein said selected elementis adhesive backed and carried on a carrier, and wherein saidassociating step includes the steps of delaminating a selected elementfrom its carrier, supporting said delaminated element with vacuum,bringing said selected element into position adjacent a media sample,and tamping said media sample and element together.
 104. The method ofclaim 103 wherein said pressing is performed by tamping.
 105. The methodof claim 104 wherein said tamping comprises: providing a fast-actingsolenoid; providing a gas spring that is driven by said solenoid; andutilizing a pressure-applying mechanism that is coupled to said gasspring and that defines a surface to press together said media and saidelement, said gas spring damping the fast action of said solenoid. 106.The method of claim 104 wherein the selected media and said selectedvalue-adding element are laminated after being pressed together.
 107. Amethod of manufacturing a plurality of adhesive-backed labels, tickets,tags, cards or other media that is laminated on a carrier, comprisingthe steps of: moving a series of media samples; delaminating at leastselected ones of said media samples from said carrier leaving, in eachinstance, an exposed adhesive media back surface; and applying adiscrete, value-adding element to said back surface of the selectedmedia, whereby only the selected ones, but not all, of said mediasamples in said series are caused to have said value-adding element.108. The method of claim 107 wherein said element is a radio frequencyidentification integrated circuit adopted to make contact with anantenna structure on said media to form a radio frequency identificationtransponder.
 109. The method of claim 107 wherein said value-addingelement is an RFID transponder or other wireless transponder.
 110. Themethod of claim 109 wherein said RFID transponder is programmed withprocess control instructions.
 111. The method of claim 110 wherein saidinstructions control a process of applying a second value-adding elementto the media to which said value-adding element is applied.
 112. Themethod of claim 109 including the step of communicating with saidtransponder before said applying step.
 113. The method of claim 112wherein said communicating includes testing, identifying, or discerninga characteristic of the transponder, or reading information stored inthe transponder, or writing information into the transponder.
 114. Themethod of claim 107 including processing said media before saidapplying.
 115. The method of claim 114 wherein said processing includesprinting on said media.
 116. The method of claim 107 wherein saidelement has a non-adhesive front surface and an adhesive back surface,and wherein said front surface of said element is applied to backsurface of said media.
 117. The method of claim 116 wherein said elementand said media are pressed together after applying to improve theadherence thereto.
 118. The method of claim 117 wherein said pressingcomprises tamping.
 119. The method of claim 107 including placing saidmedia on a carrier after said element is applied, creating acarrier-element-media laminate.
 120. The method of claim 119 wherein thefinal carrier is the same as or different from the initial carrier. 121.The method of claim 119 including passing said carrier-element-medialaminate through pinch rollers.
 122. The method of claim 107 wherein anelement is applied under computer program control selectively only tocertain of said media and not to others.
 123. The method of claim 107wherein said carrier is intermittently fed, and is paused or stoppedduring said applying step.
 124. The method of claim 107 including movingsaid element into position for said applying step on a dispensing devicewhich is retracted after an element is applied to a media.
 125. Themethod of claim 107 wherein said media are fed in a first direction, andwherein said elements are fed into said position in a directiontransverse to said first direction.
 126. An article of manufacturecomprising a web, cassette, or other carrier carrying a series oflabels, tickets, tags, cards or other media, said carrier beingcharacterized by selected ones, but not all, of said media havingassociated therewith at least one value-adding element.
 127. An articleof claim 126 wherein said element is a radio frequency identificationintegrated circuit adopted to make contact with an antenna structure onsaid media to form a radio frequency identification transponder. 128.The article of claim 126 wherein said element comprises an RFIDtransponder or other wireless transponder.
 129. The article of claim 128wherein said media having an associated value-adding element exhibitsvisible indicia which indicates whether the transponder is defective,inoperative, misprogrammed, or has another characteristic or attribute.130. The article of claim 128 wherein said media having an associatedelement exhibits information read from or stored in said transponder.131. The article of claim 126 wherein said value-adding elementcomprises a second media.
 132. The article of claim 131 wherein thesecond media is a promotional device.
 133. The article of claim 126wherein said media having an associated value-adding element exhibitstext or other indicia indicating whether the media or element has faileda test.
 134. The article of claim 133 wherein said indicia exhibits testresults or a date or time stamp.
 135. The article of claim 126 whereinthe carrier carries a plurality of media having differentcharacteristics.
 136. The article of claim 135 wherein the differentcharacteristics include size, material composition, type, stock, orother specifications.
 137. The article of claim 126 wherein the carriercarries a plurality of elements having different characteristics. 138.The article of claim 126 wherein the carrier supports selected mediahaving plural elements.
 139. The article of claim 126 wherein thecarrier supports selected media having selectively differentpreprocessing or postprocessing.
 140. The article of claim 126 whereinthe carrier carries selected media adapted to be applied in groups. 141.An on-demand printer for printing information on a series of labels,tickets, tags, cards or other media, comprising: a media feeder; andmeans for associating a discrete value-adding element with certainmedia, but not with other media, in a series of said media.
 142. Theprinter of claim 141 wherein said element is a radio frequencyidentification integrated circuit adopted to make contact with anantenna structure on said media to form a radio frequency identificationtransponder.
 143. The printer of claim 141 wherein said value-addingelement is an RFID transponder or other wireless or other wirelesstransponder.
 144. The printer of claim 143 further comprising means forcommunicating with said transponder.
 145. The printer of claim 144wherein said communicating step comprises (i) testing, identifying, ordiscerning a characteristic of the transponder, (ii) reading informationstored in the transponder, or (iii) writing information into thetransponder.
 146. The printer of claim 141 further comprising means forprocessing said media before said value-adding element is associatedwith said selected media.
 147. The printer of claim 146 wherein saidmeans for processing includes a printing apparatus.
 148. The printer ofclaim 147 wherein said value-adding element is an RFID transponder orother wireless or other wireless transponder, and wherein said printeror printer accessory includes means for communicating with saidtransponder.
 149. The printer of claim 148 wherein said printingapparatus is responsive to said means for communicating and prints aresult of said communicating with said transponder.
 150. The printer ofclaim 148 wherein said printing apparatus is responsive to said meansfor communicating and prints an indication of a defect or anothercharacteristic or attribute of said transponder.
 151. The printer ofclaim 148 wherein said printing apparatus is responsive to said meansfor communicating and prints information based on data read from orstored in said transponder.
 152. The printer of claim 142 wherein saidmeans for associating is controlled by a computer program. 153.Apparatus for associating a selected element with a selected label,ticket, tag, card or other media, at least one of which element andmedia is adhesive-backed and carried on a carrier, comprising: means fordelaminating said one element or media from its carrier; means forsupporting said delaminated element or media; means for bringing saidsupported element or media into a position contiguous with the other ofsaid element or media; and means for pressing said element and mediatogether to cause adherence.
 154. The apparatus of 153 wherein saidmeans for pressing comprises a tamper.
 155. The apparatus of claim 154wherein said tamper comprises: a fast-acting solenoid; a gas spring thatis driven by said solenoid; and a pressure-applying mechanism that iscoupled to said gas spring and that defines a surface to press togethersaid media and said element, said gas spring damping the fast action ofsaid solenoid.
 156. The apparatus of 136 wherein said means forsupporting utilizes a vacuum, wherein said tamper is reciprocable, andwherein said tamper includes a bellows through which the vacuum isdelivered to said supported element or media.
 157. The apparatus of 136wherein said supported media is adhesive backed, and wherein saidapparatus includes means for relaminating said supported media.
 158. Theapparatus of 153 wherein said value-adding element is an RFIDtransponder, and wherein said apparatus includes means for programmingor reprogramming the transponder.
 159. The apparatus of 153 wherein saidmeans for bringing includes means for reciprocating said selectedelement into said contiguity and then withdrawing to leave the element.160. For use in adhering a label, ticket, tag, card or other media to avalue-adding element, one of which media and element have an exposedadhesive surface, a reciprocable tamping applicator mechanismcomprising: a fast-acting solenoid; a gas spring that is driven by saidsolenoid; and a pressure-applying mechanism that is coupled to said gasspring and that defines a surface that presses together the media andthe element, said gas spring damping the fast action of said solenoid.161. The mechanism of claim 160 including a return spring that returnssaid pressure-applying mechanism after a stroke by said solenoid. 162.The mechanism of claim 161 further comprising a plenum containing saidsolenoid and said gas spring, as well as a bellows that is disposedbetween said plenum and said pressure-applying mechanism.
 163. Themechanism of claim 162 wherein said surface is perforated, and whereinsaid mechanism includes means coupled to said plenum for developing avacuum in said plenum.
 164. A promotional label, ticket, tag, card orother media having thereon or associated therewith: one or more RFIDtransponders programmed with predetermined data representing informationabout, or of expected interest to, a particular prospect or class ofprospects for a given product, service, or appeal; and one or moreprintings containing information about, or of expected interest to, saidparticular prospect or class or prospects, the printed and programmedinformation being coordinated and integrated to evoke a predeterminedresponse from said class of prospects.
 165. The media of claim 164including a plurality of RFID transponders.
 166. The media of claim 165wherein at least one of said one or more RFID transponders is programmedwith process control instructions.
 167. The media of claim 166 whereinsaid instructions control a process of associating a second value-addingelement with the media with which said value-adding element isassociated.
 168. The media of claim 164 including a peelable orrepostionable RFID transponder.
 169. The media of claim 164 including aplurality of separately applied value-adding elements.
 170. The media ofclaim 164 including a chipless RFID transponder.
 171. The media of claim170 wherein said RFID transponder is programmed with process controlinstructions.
 172. The media of claim 171 wherein said instructionscontrol a process of associating a second value-adding element with themedia with which said value-adding element is associated.